Fe76Si9.6B8.4P6 glassy powder soft-magnetic cores with low core loss prepared by spark-plasma sintering

Highlights: · We prepare a bulk glassy alloy magnetic core by spark-plasma sintering. · The magnetic core shows good soft magnetic properties and much smaller core loss. · The saturation magnetization is 1.44 T and the coercive force is 31 A/m. · The effective permeability at 1 kHz is 1320. · The core loss at 10 kHz and maximum induction of 0.2 T is only 47 W/kg. - Abstract: Large glassy alloy discs (12 mm diameter, 1 mm thickness) of high relative density (∼98%) were prepared by spark plasma sintering. The bulk magnetic cores (12 mm outer diameter, 6 mm inner diameter, 1 mm thickness) exhibit good soft magnetic properties: saturation magnetization is 1.44 T, coercivity is 31 A/m, and effective permeability at 1 kHz is 1320. They also exhibit much lower loss than a silicon steel core; core loss at 10 kHz and maximum induction of 0.2 T is only 81.7 W/kg.